• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Te 630 Sub-frame Mod

Is there a top rack and side rack mount combined together for the 630. I am thinking that side mounts typically attach to footpegs or similar ? -- this would allow the top rack get the benefit of that mount -- and therefore relieving subframe from the top rack mount stress
 
I'm studying right now a rack that attach to rear footpegs. But the simulations shows there aren't great benefits for the subframe. I will keep you up to date.
 
@SilverBullet -- yep, you are right. I can see now -- it only bolts to the subframe... strange that there is nothing that out there that can distribute the load form subframe to frame
 
BTW, on page 3 of this thread is my original posts on developing this solution, should you want to read about how it all came about.
http://www.cafehusky.com/threads/new-rack-for-te630-coming-from-turbo-city.20567/#post-179933

I have over two thousand miles on my 630 now, more than half of it on very harsh terrain with 25-35lbs on my cargo rack, and there are no signs of fatigue whatsoever anywhere on my subframe. As I've mentioned, a proper weld job is a more clean way to reinforce the sub on these bikes, but it's a lot more hassle and costs more in time and energy not to mention gaining access to a competent welder.

Full size patterns for the plates in PDF for download are on the original thread above, post 102.
 
Well.......I'm going to get this done CJ. I finally got my bike back with a NEW, fully covered under warranty, subframe. I wouldn't hesitate to at least recommend this to anyone as anything less is just frugal, especially if you want to haul any kind of weight on the back of the 630. Just my 2 cents.....
 
I have had a lot of inquiries for the templates for my reinforcing plates, so it seems to be popular. Have yet to hear from anyone that it didn't work or was too hard to do.

Seems sourcing stock can be a challenge in some locales, so a quick search online turned up these folks in KY. They will cut 6061 'aircraft grade' aluminum flat bar and ship it, a 4' piece of 3/16x 2" bar is about $12. Three feet is plenty to get two plates out of. How can you beat that? http://www.metalsdepot.com/products/alum2.phtml?page=flat&LimAcc= &aident=

BTW, 6061 has twice the tensile strength as standard aluminum sheeting. Very easy to cut out with a hacksaw and finish the edges with a grinder and hand file.
 
I've got my plates cut out, been waiting three weeks on the "U-bolts" from Husky. Can't take my footpegs off because I've got an Outback Rack coming from TCI. :applause:

Thanks again Chris!
 
DYNOBOB said:
I've got my plates cut out, been waiting three weeks on the "U-bolts" from Husky. Can't take my footpegs off because I've got an Outback Rack coming from TCI. :applause:

Thanks again Chris!
Click to expand...
I ordered a second set of U bolts myself, for the subframe mod. I should get started with a bunch of work on the bike in a couple weeks.
 
Good deal guys. I'm over three thousand miles now, half hard trails, no issues, always cargo on the rack. The Kolpin pack has been particularly handy for getting longer range.
 
Are you interested in making some of the plates available for sale? I have a weldor available and it would great to buy these plates ready made.

pinocono said:
That looks great, Kenneth. It's funny, I just finished pulling my subframe off about an hour ago, and will be doing the same mod as you. I work in a precision sheet metal shop, so it'll be a snap for me to get it done.
Click to expand...
 
Wrryder, I never really thought about making plates. They are very simple to fab and can be done with a hack saw and a hand file in a few minutes, for pennies. The welding is the trick, and needs to be done properly. Of course you have to pull the bike apart too, then put it together again and not everyone is going to do that. If you have TIG welding equipment available, and good skills, go for it! Listen carefully to any stock sub-frame and you will hear it pleading for help....
 
I have a good welder here in town, just looking for an easy way to come up with plates.

Kenneth Webb said:
Wrryder, I never really thought about making plates. They are very simple to fab and can be done with a hack saw and a hand file in a few minutes, for pennies. The welding is the trick, and needs to be done properly. Of course you have to pull the bike apart too, then put it together again and not everyone is going to do that. If you have TIG welding equipment available, and good skills, go for it! Listen carefully to any stock sub-frame and you will hear it pleading for help....
Click to expand...
 
So far so good with my fix. Lots of very tough off road and usually carry too much. I'm also using the Wolfman racks, which I believe helps.

IMAG0509.jpg
 
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